Electronic textiles can provide several advantages, including enhanced accessibility, comfort, and durability, flexibility, and stretchability in diverse fields such as sensors and actuators, energy generators, transistors, and capacitors (Bae et al. 2014; Choong et al. 2014; Nassour and Hamker 2019; Ryu et al. 2018). Electronic textiles are also soft and offer close contact between electronics and the skin, which is challenging for bulky and planar film-based devices. The ubiquitous nature of textiles provides an ideal medium for a wearable sensor platform to monitor physiological activities and environments. Various approaches have attempted to embed conductive materials into textile structures, including coating or printing on the textile surface (Li et al. 2020; Uzun et al. 2019), stitching patterns with conductive thread with a sewing machine or embroidery machine (Shin et al. 2018), and developing woven or knitted electronic textiles with functional yarns (Fan et al. 2020; Wu et al. 2018). The knit structure of these textiles is composed of consecutive rows of interconnected yarn loops that give the material flexibility for outstanding fit, high elasticity, and excellent elastic recovery (Trangsirinaruenart and Stylios 2019). The combination of elastane fiber with conventional yarns provides loop dimensions of shape, length, and width that are crucial parameters of the physical, mechanical and dimensional properties of knitted fabrics (Azim et al. 2014; Sitotaw 2018).
In recent years, data gloves with various sensor units have been introduced as an essential wearable platform for applications in virtual/augmented reality interfaces (He et al. 2019; Zhu et al. 2020) and health monitoring, including of physical rehabilitation for post-stroke patients (Heo et al. 2020; Kim et al. 2019; Wang et al. 2020). However, existing glove systems have multiple drawbacks, such as lack of robustness and washability with the integration of rigid electronics onto a glove platform, the need for multiple complicated processes such as attachment of a sensory unit, and the bulkiness of the system. Several efforts have been made to integrate functional fiber sensors into textiles to provide flexibility and mobility. However, there are still limitations to large-scale deployment, including the relatively high cost and manufacturing time (Ou et al. 2019). Additionally, a customizable design for shape, size, and fit are critical to ensure conformal contact between the textiles and body. With the development of computer-aided design (CAD), a digital CAD knitting system can facilitate design development with various 3D shapes for custom-fit and embedded patterns using various materials. CAD also allows us to modify the dimensions and structure through user-centered interfaces and visualize virtually simulated images. In future production, a seamless manufacturing process would enable economical utilization of materials and energy without waste. Accordingly, programmable and reconfigurable engineering design approaches with a structured methodology, which describes interrelationships among requirements, design parameters and characteristics, must be established in wearable electronic textile development.
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In this study, we present a systematic structured design and development framework for a seamless smart glove as a motion sensor platform using the computer-aided digital knitting process modified from the previously developed wearable motherboard design and development framework (Park and Sundaresan 2001; Rajamanickam et al. 1998). The requirements of the wearable glove sensor system are determined, and the specific sensing and comfort properties are consolidated into five design components. Based on the design components, the appropriate materials and the fabrication technology are applied. Digital knitting technology is utilized for the development of the glove sensory system through a programmable and automated process for creating a seamless three-dimensional (3D) glove. Finally, two prototype seamless glove sensor systems worn on the human hand and robotic hand are demonstrated.
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